KTM 500 EXC - Converting to Cush Hub

Discussion in 'Thumpers' started by mdlafferty, Dec 14, 2016.

  1. mdlafferty

    mdlafferty Adventurer

    Joined:
    Feb 21, 2013
    Oddometer:
    34
    Location:
    Victoria BC
    I am planning to convert to a cush hub on my 2016 500EXC.
    I received quotes from Woody's Wheelworks and DubyaUSA/Talon, who both seem like great suppliers with great products, but when I convert the mighty US dollars to my puny Canadian dollars the price is eye watering.
    The other option I was considering is using an LC4 640 Enduro rear wheel. Apparently this wheel is a direct bolt on replacement and this conversion has been described in many posting here. I checked the price with my local KTM dealer for a new complete wheel and it is the cheapest option. The KTM dealer gave me a price for:
    58410001544 2005 Enduro 18" Rear Wheel Damped
    58310050344 Sprocket Support
    54610459000 Damping Rubber (Qty of 6)
    Total price is around $950 Canadian ($716US)
    Still not cheap but much better.
    I assume that these are still available from him since he was able to give me the prices.

    Before I go ahead and order this, I wanted to triple check with the experts here to be sure that I'm on the right track and not ordering $950 worth of wrong parts. I'm expecting to get the parts, install my tire on the new wheel, move the brake disk and sprocket onto the new hub and the wheel will line up and bolt right on using the stock 500EXC axle spacers. Is there anything I'm missing here or any custom fabrication work that will be required?
    All your words of wisdom are appreciated. Thanks
    Mark
    #1
  2. Motomochila

    Motomochila Moto Scientist and time traveler

    Joined:
    Sep 30, 2007
    Oddometer:
    1,702
    Location:
    N 34 22.573' W 118 34.328'
    Got a Rad Cush rear hub and excel wheel for sale $500. Almost new. 2014 EXC 500

    Jerry, LA area.
    #2
  3. mdlafferty

    mdlafferty Adventurer

    Joined:
    Feb 21, 2013
    Oddometer:
    34
    Location:
    Victoria BC
    Jerry;
    I'm interested. How can I contact you?
    Thx
    Mark
    #3
  4. Motomochila

    Motomochila Moto Scientist and time traveler

    Joined:
    Sep 30, 2007
    Oddometer:
    1,702
    Location:
    N 34 22.573' W 118 34.328'
    send me a PM with your email and phone number. I'm in Dallas for business till Friday. When I return I will snap a few photos and send them off your way.

    Jerry
    #4
  5. SRG

    SRG Long timer

    Joined:
    Nov 18, 2004
    Oddometer:
    3,408
    Location:
    Central Va.
    I'd like to know the answer to the original question - is the 640 wheel a direct swap onto the 500's?
    #5
  6. Bluetonguejak

    Bluetonguejak Pretend racer

    Joined:
    Sep 16, 2009
    Oddometer:
    3,877
    Location:
    Gippsland
    Dunno about the EXC500, but the axle size of a '13 SXf450 is larger than that of a LC4 640 and has different (slightly) disc/sprocket distance/offset.

    Worth comparing axle sizes and distances/offsets first.

    I 'modified' a LC4 sprocket carrier to suit my partners SXF (so i could use existing wets on LC4 rims between SM race bikes) which involved fitting different bearings and modifying/machining new spacers - you dont want to go to this hassle if you can get a rim to fit straight-up!

    BOL
    #6
  7. ChasM

    ChasM Been here awhile

    Joined:
    Nov 27, 2007
    Oddometer:
    863
    Location:
    Loomis, CA (Sacramento area)

    Yes they are. I got one from Munn Racing several years ago for a little over $300 for my '04 KTM 540 EXC.
    #7
  8. Dao1

    Dao1 Long timer

    Joined:
    Mar 17, 2014
    Oddometer:
    2,213
    Location:
    Austin TX
    This is the LC4 cush hub wheel I used on my '10 FE390. Perfect fit.
    The Rim has the mfr, BEHR, on it.

    When you purchase the KTM sprocket support kit, there is (should be) a new, narrow axle spacer(shown in pic sitting on the sprocket support) that goes w/ the cush sprocket support. I couldn't figure out whether this new spacer is used in conjunction w/ the two existing spacers
    on the LC4 wheel or whether that side spacer gets replaced w/ the new one on the sprocket support. SO I decided to use all three spacers on my rr wheel. Worked just fine.
    [​IMG]

    Here's the wheel on bike.
    [​IMG]

    About the only thing I would throw caution out is....
    did KTM change the rear axle diameter on the newer offroad & EXC bikes?
    If they did, you will need to rethink this setup.
    #8
  9. mdlafferty

    mdlafferty Adventurer

    Joined:
    Feb 21, 2013
    Oddometer:
    34
    Location:
    Victoria BC
    For my 2016 500EXC I measured the axle diameter at 20mm and the hub width including spacers at 78 mm.

    Dao1;
    Thanks for your info and photos.
    Could I trouble you to measure your axle diameter and the width of your hub including sprocket carrier and spacers to see if they match mine?
    Mark
    #9
  10. Whodatschrome

    Whodatschrome Long timer

    Joined:
    May 4, 2015
    Oddometer:
    4,571
    Location:
    North of North Plains
    Yeah, but you can get any color hub and wheel you want from Woodys...
    #10
    WallyB likes this.
  11. Bitingdog

    Bitingdog That's not my dog

    Joined:
    Apr 2, 2015
    Oddometer:
    19,526
    Location:
    The bad side of the PNW
    Yes, but don't switch over the rotor and sprocket - get jobber stuff from RMATV or the like. Keep the cush wheel with a DOT tire, and a full-on knobby for the stock wheel. That's what I did, and it's great
    #11
    Tallbastid likes this.
  12. davesupreme

    davesupreme grand poobah

    Joined:
    May 1, 2011
    Oddometer:
    5,266
    Location:
    palm harbor, fla
    i gotta used RAD hub from woody's a few years ago.... i also have a KTM hub that i used for my SMR rig.... the KTM hub is a better piece.... the bearings fit really loose in the RAD hub..... i would go KTM if i was buying another.... they're nice on the street, but heavy for woods riding.... i like my un-cush hub alot better for woods riding.....
    #12
    Bitingdog likes this.
  13. massholejim

    massholejim Been here awhile

    Joined:
    Aug 25, 2014
    Oddometer:
    389
    Just got a warp nine for my 2010 husaberg 450 ,500 and change with disc and sprocket cush drive also check out mox sprockets out of New Zealand cush sprocket with replaceable parts you can change just outer ring when you change chain and sprockets or if you want to Shane gearing.
    #13
  14. Dao1

    Dao1 Long timer

    Joined:
    Mar 17, 2014
    Oddometer:
    2,213
    Location:
    Austin TX
    Mark,
    I don't have the rr wheel to measure hub width. SOrry about that.

    Let me double check on the rr axle dia.
    #14
  15. mdlafferty

    mdlafferty Adventurer

    Joined:
    Feb 21, 2013
    Oddometer:
    34
    Location:
    Victoria BC
    I got confirmation from the KTM dealer that all the parts listed in my first post are still available. The wheel is special order from Austria. 3-4 weeks delivery.

    As another alternative, from Rolling Hobo's website, he used a Haan cush wheel from Holland for his KTM 500 Adventure build. Haan's representative in Canada is Blackfoot Direct in Calgary. Blackfoot quoted me $980 Canadian (736 US) with 2 month delivery and free shipping.

    I'm thinking of going with the Haan.
    #15
  16. StevenD

    StevenD Hmmmm, dirt!

    Joined:
    Aug 3, 2005
    Oddometer:
    1,512
    Location:
    Holland, Amserdammed
    Haan is top noch. Go for it.

    Verstuurd vanaf mijn SM-G935F met Tapatalk
    #16
  17. Minidragon

    Minidragon Long timer

    Joined:
    Feb 10, 2014
    Oddometer:
    1,338
    Location:
    Overthere
    I would maybe gone the Warp9 way too, cush hub,included are your choice of hub color,sprocket size and rotor,starting at $529 not too bad
    #17
    massholejim likes this.
  18. RideFreak

    RideFreak Torque Junky

    Joined:
    Apr 17, 2009
    Oddometer:
    16,560
    Location:
    Out in the NM Dez somewhere
    #18
  19. Max Kool

    Max Kool Xtankteam™

    Joined:
    Jan 19, 2004
    Oddometer:
    5,023
    Location:
    Los Angeles
    Wow that's a bargain!
    #19
  20. Hohmie

    Hohmie Long timer

    Joined:
    Jan 23, 2013
    Oddometer:
    2,144
    Location:
    Bend Or
    Does any body have experience with the wheels in the link?
    #20